Staple drive assembly

ABSTRACT

A staple drive assembly includes an actuation sled and at least one staple pusher. The staple drive assembly is adapted to fit within a staple cartridge having a plurality of staples and a corresponding number of retention slots. The at least one staple pusher includes at least one pusher plate for releasably engaging a backspan of a staple. The staple pusher may include a plurality of pusher plates that may be laterally and longitudinally spaced apart. An actuation member has at least one angled camming surface for engaging a complimentary angled surface of the at least one staple pusher. Camming engagement between the actuation member and the at least one staple pusher causes vertical movement of the at least one staple pusher. Lateral and longitudinal offset of the actuation member camming surfaces and the corresponding staple pusher following surfaces improves stability and control of the staple pusher during firing.

BACKGROUND

1. Technical Field

The present disclosure relates to stapling apparatus. More particularly,the present disclosure relates to a staple drive assembly for use in astaple cartridge of a stapling apparatus.

2. Background of Related Art

Surgical stapling apparatus are widely used in surgical procedures tofasten body tissue quickly and efficiently by driving fasteners, orstaples into the tissue. In certain types of stapling apparatus, a drivemember moves transversely to the direction the staples are to be driven.Typically, such stapling apparatus employ a number of staple pusherelements located in grooved slots of a staple cartridge and arranged endto end in rows. Under normal operation, the transversely moving drivemember contacts a cam member on the staple pusher thereby pushing thestaple pusher vertically in the grooved slot. The staple pushertransmits linear motion from the drive member to the staples. The rowsof staples are thereby driven into the body tissue to be fastened.

Several issues arise in designing staple pushers for driving one or moresurgical staples. If the forces applied to the staple pusher are noteffectively balanced, there is a tendency for the staple pusher to twistwithin the grooved slot and/or bind against the walls of the groovedslot. Additionally, a single point of contact between the actuation sledand the staple pusher may create a rocking point on the staple pusherwhich can cause the staple pusher to exit the staple cartridge in anunbalanced manner which may result in non-uniform staple formation.Moreover, staple pushers for driving a plurality of staples may offermore resistance to longitudinal movement of the drive member. It isdesirable that the staple pusher permit application of a relativelysmooth ejection force throughout the operation of the drive member. Itis also desirable that the stapling apparatus form a plurality offinished staples having a substantially uniform configuration.

Various staple pusher and cam bar arrangements are known. See, forexample, U.S. Pat. Nos. 4,955,959; 4,978,049; 5,395,034; 5,630,541;5,662,258; 6,131,789 and D278,081.

SUMMARY

The present disclosure is directed towards a staple drive assembly foruse in a staple cartridge. The staple drive assembly includes anactuation sled and at least one staple pusher. The staple cartridgeincludes a tissue contacting surface having a number of retention slotswherein each retention slot is adapted for releasably receiving astaple. The staple cartridge may include a guide channel extending froma proximal portion to a distal portion along its longitudinal axis. Inone embodiment, the staple cartridge is adapted for use in a surgicalstapler having a drive mechanism.

The actuation sled includes a base, at least one camming member and aguide member. Each camming member includes a first or leading cam wedgeand a second or trailing cam wedge. The leading and trailing cam wedgesare laterally and longitudinally spaced apart from one another. Spacingof the cam wedges apart, both laterally and longitudinally, creates asituation in which the staple pusher is contacted at points offset intwo planes so that as the staple pusher is driven, it is controlled anddriven substantially perpendicular to the tissue plane of the cartridgewithout rocking in any direction which would compromise driving thestaple perpendicular to the tissue contacting plane. Additionally, eachcam wedge includes a first drive face and a second drive face. In oneembodiment, the first drive faces form first drive angles with respectto the base and second drive faces form second drive angles with respectto a plane that is substantially parallel to the base. The guide memberis adapted for slidably engaging the guide channel for aligning andguiding the actuation sled as it translates through the staplecartridge. In one embodiment, first drive faces are oriented such thatfirst drive angles may be in a range of about 30° to about 40° while thesecond drive faces are oriented such that second drive angles may be ina range of about 15° to about 25°.

Each staple pusher includes at least one pusher plate and at least onecam member. In one embodiment, each staple pusher includes three pusherplates and two cam members. In an alternate embodiment, each staplepusher includes one pusher plate and two cam members. In a furtherembodiment, each staple pusher includes two pusher plates and two cammembers. First and second cam members are adapted for slidably engagingone of the cam assemblies of the actuation sled. Each cam memberincludes first and second cam surfaces that define respective first andsecond engagement or receiving angles that are complementary to thefirst and second drive angles. In one embodiment, the first receivingangles may be in a range of about 15° to about 55° while the secondreceiving angles may be in a range of about 5° to about 35°. In anotherembodiment, the first receiving angles may be in a range of about 25° toabout 45° while the second receiving angles may be in a range of about10° to about 30°. In a further embodiment, the first receiving angle maybe in the range of about 30° to about 40° while the second receivingangle may be in the range of about 15° to about 25°. The first andsecond cam members are longitudinally and laterally spaced apart tocomplement the arrangement of the leading and trailing cam wedges of theactuation sled.

Distal travel of the actuation sled through the staple cartridge causesthe sequential engagement of the actuation sled and the staple pushersdisposed in the staple cartridge. As the actuation sled moves along thelongitudinal axis of the staple cartridge, the first drive facesslidably engage the first cam surfaces thereby urging each staple pusherin a generally vertical direction. As the actuation sled continues tomove distally, the second drive faces slidably engage the second camsurfaces of each staple pusher to continue to drive each staple pusherin a generally vertical direction while the first drive faces disengagefrom the first cam surfaces. Each camming member contacts each staplepusher in at least two longitudinally spaced locations for urging eachstaple pusher vertically. This longitudinally staggered arrangement ofthe drive faces in cooperation with the complementary staggeredarrangement of the cam members maximizes the longitudinal stability ofthe staple pusher as it moves vertically. Additionally, the first andsecond drive angles in cooperation with the complementary first andsecond receiving angles contribute to the improved longitudinalstability of each staple pusher.

In another embodiment of the present disclosure, an actuation sledincludes substantially the same or similar components, but the first andsecond drive angles may be in a range of about 5° to about 35° while thesecond drive angles may be in a range of about 20° to about 55°. Inanother embodiment, first drive angles may be in a range of about 10° toabout 30° while second drive angles may be in a range of about 25° toabout 45°. In a further embodiment, first drive angles may be in a rangeof about 15° to about 25° while second drive angles may be in a range ofabout 30° to about 40°. During distal movement of the actuation sled,the first drive faces slidably engage the second cam surfaces urgingeach staple pusher in a generally vertical direction. As the actuationsled continues to move distally, the second drive faces engage first camsurfaces as the first drive faces disengage from the second camsurfaces. Applicants have found that providing a cam wedges with a firstdrive surface angle which is less than the second drive angle provides asmooth firing stroke. Similar to the previous embodiment, longitudinalstability of the staple pusher is maximized by the longitudinallystaggered (i.e. spaced apart) cam members in cooperation with thecomplementarily staggered cam wedges. In addition, when the first driveangle is less than the second drive angle, the staple pusher contactsboth drive surfaces as contact with the staple pusher transitions fromcontacting one drive surface to the other drive surface.

In a further embodiment of the present disclosure, an actuation sled isdisclosed that includes the same or substantially similar components. Inthis embodiment, the actuation sled includes first and second cammingmembers, a base, and a guide member. Each camming member furtherincludes first and second cam wedges that are longitudinally spacedapart and define a drive angle with respect to the base. The first andsecond cam wedges of each camming member are laterally spaced apart aswell.

Another embodiment of the present disclosure includes an actuation sledthat has the same or substantially similar components. According to thisembodiment, the actuation sled includes first and second cammingmembers, a base, and a guide member. Each camming member furtherincludes first and second cam wedges that are laterally spaced apartfrom each other and define a plurality of drive angles with respect tothe base. In particular, each cam wedge defines a first set of driveangles that may be in the range of about 15° to about 25° and a secondset of drive angles that may be in the range of about 26° to about 36°.In another embodiment, each cam wedge defines a first set of driveangles that may be in the range of about 17° to about 23° and a secondset of drive angles that may be in the range of about 28° to about 34°.In a further embodiment, each cam wedge defines a first set of driveangles that may be in the range of about 19° to about 21° and a secondset of drive angles that may be in the range of about 30° to about 32°.

In an alternate embodiment of the present disclosure, an actuation sledis described having the same or substantially similar components.According to this embodiment, the actuation sled includes first andsecond camming members, a base, and a guide member. Each camming memberfurther includes first and second cam wedges that are laterally andlongitudinally spaced apart from each other and define a plurality ofdrive angles with respect to the base. In particular, each cam wedgedefines a first set of drive angles that may be in the range of about15° to about 55° and a second set of drive angles that may be in therange of about 5° to about 35°. In another embodiment, each cam wedgedefines a first set of drive angles that may be in the range of about25° to about 45° and a second set of drive angles that may be in therange of about 10° to about 30°. In a further embodiment, each cam wedgedefines a first set of drive angles that may be in the range of about30° to about 40° and a second set of drive angles that may be in therange of about 10° to about 30°.

In yet another embodiment of the present disclosure, each of thedescribed actuation sleds may be included at a distal end of a cam baror actuation member in a surgical stapling apparatus.

As will be appreciated from the disclosure, controlled driving of thestaple pushers can be maximized by providing cam wedges which are offsetboth laterally and longitudinally from each other with each drivesurface having a first drive angle which is less than the second driveangle.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the presently disclosed staple drive assembly aredescribed herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of a staple drive assembly showing anactuation sled and a staple pusher in accordance with an embodiment ofthe present disclosure;

FIG. 2 is a perspective view of an endoscopic surgical staplingapparatus;

FIG. 3 is an exploded perspective view of a staple cartridge, staples,staple pushers and an actuation sled;

FIG. 4 is a top plan view of the staple cartridge of FIG. 4 with theactuation sled in an initial position;

FIG. 5 is a side cross-sectional view of a proximal portion of thestaple cartridge taken along section line 5-5 of FIG. 4;

FIG. 6 is a front perspective view of the staple pusher of FIG. 1;

FIG. 7 is a rear perspective view of the staple pusher of FIG. 1;

FIG. 8 is a top plan view of the staple pusher of FIG. 1;

FIG. 9 is a side cross-sectional view taken along section line 9-9 ofFIG. 8;

FIG. 10 is a side cross-sectional view taken along section line 10-10 ofFIG. 8;

FIG. 11 is a front perspective view of the actuation sled of FIG. 1;

FIG. 12 is a rear perspective view of the actuation sled of FIG. 1;

FIG. 13 is a top plan view of the actuation sled of FIG. 1;

FIG. 14 is a side cross-sectional view taken along section line 14-14 ofFIG. 13;

FIG. 15 is a side cross-sectional view taken along section line 15-15 ofFIG. 13;

FIG. 16 is a side cross-sectional view of the staple drive assembly ofFIG. 1 showing the initial engagement between the cam members of thestaple pusher of FIG. 6 and the cam wedges of the actuation sled as theactuation sled moves in the direction of arrow A;

FIG. 17 is a side cross-sectional view of the staple drive assembly ofFIG. 1 showing the continued engagement between the cam members of thestaple pusher of FIG. 6 and the cam wedges of the actuation sled as theactuation sled continues to move in the direction of arrow A;

FIG. 18 is a top plan view taken along section line 18-18 of the stapledrive assembly of FIG. 17;

FIG. 19 is a front perspective view of an actuation sled according toanother embodiment of the present disclosure;

FIG. 20 is a rear perspective view of the actuation sled of FIG. 19;

FIG. 21 is a top plan view of the actuation sled of FIG. 19;

FIG. 22 is a side cross-sectional view of the actuation sled of FIG. 19taken along section line 21-21 of FIG. 21;

FIG. 23 is a side cross-sectional view of the actuation sled of FIG. 19taken along section line 23-23 of FIG. 21;

FIG. 24 is a side cross-sectional view of another embodiment of a stapledrive assembly including the actuation sled of FIG. 19 showing theinitial engagement between the cam members of the staple pusher of FIG.6 and the cam wedges of the actuation sled as the actuation sled movesin the direction of arrow A;

FIG. 25 is a side cross-sectional view of the staple drive assembly ofFIG. 24 showing the continued engagement between the cam members of thestaple pusher of FIG. 6 and the cam wedges of the actuation sled as theactuation sled continues to move in the direction of arrow A;

FIG. 26 is a rear perspective view of an alternate embodiment of astaple pusher in accordance with the present disclosure;

FIG. 27 is a top plan view of the staple pusher of FIG. 26;

FIG. 28 is a rear perspective view of another embodiment of a staplepusher in accordance with the present disclosure;

FIG. 29 is a top plan view of the staple pusher of FIG. 28;

FIG. 30 is a front perspective view of an actuation sled according toanother embodiment of the present disclosure;

FIG. 31 is a rear perspective view of the actuation sled of FIG. 30;

FIG. 32 is a top plan view of the actuation sled of FIG. 30;

FIG. 33 is a side cross-sectional view taken along section line 33-33 ofFIG. 32;

FIG. 34 is a side cross-sectional view taken along section line 34-34 ofFIG. 32;

FIG. 35 is a side cross-sectional view of another embodiment of a stapledrive assembly including the actuation sled of FIG. 30 showing theinitial engagement between the cam members of the staple pusher of FIG.6 and the cam wedges of the actuation sled as the actuation sled movesin the direction of arrow A;

FIG. 36 is a side cross-sectional view of the staple drive assembly ofFIG. 35 showing the continued engagement between the cam members of thestaple pusher of FIG. 6 and the cam wedges of the actuation sled as theactuation sled continues to move in the direction of arrow A;

FIG. 37 is a front perspective view of an actuation sled according toanother embodiment of the present disclosure;

FIG. 38 is a rear perspective view of the actuation sled of FIG. 37;

FIG. 39 is a top plan view of the actuation sled of FIG. 37;

FIG. 40 is a side cross-sectional view of the actuation sled of FIG. 39taken along section lines 40-40 of FIG. 39;

FIG. 41 is a side cross-sectional view of the actuation sled of FIG. 39taken along section line 41-41 of FIG. 39;

FIG. 42A is bottom perspective view of a pusher member according to anembodiment of the present disclosure;

FIG. 42B is side perspective view of the pusher member of FIG. 42A;

FIG. 43 is a side cross-sectional view of another embodiment of a stapledrive assembly including the actuation sled of FIG. 37 showing theinitial engagement between the cam members of the staple pusher of FIG.42A and the cam wedges of the actuation sled as the actuation sled movesin the direction of arrow A;

FIG. 44 is a side cross-sectional view of the staple drive assembly ofFIG. 43 showing the continued engagement between the cam members of thestaple pusher of FIG. 42A and the cam wedges of the actuation sled asthe actuation sled continues to move in the direction of arrow A;

FIG. 45 is a front perspective view of an actuation sled according toanother embodiment of the present disclosure;

FIG. 46 is a rear perspective view of the actuation sled of FIG. 45;

FIG. 47 is a top perspective view of the actuation sled of FIG. 45;

FIG. 48 is a side cross-sectional view of the actuation sled of FIG. 47taken along section lines 48-48 of FIG. 47;

FIG. 49 is a side cross-sectional view of the actuation sled of FIG. 47taken along section lines 49-49 of FIG. 47;

FIG. 50 is a side cross-sectional view of another embodiment of a stapledrive assembly including the actuation sled of FIG. 45 showing theinitial engagement between the cam members of the staple pusher of FIG.6 and the cam wedges of the actuation sled as the actuation sled movesin the direction of arrow A;

FIG. 51 is a side cross-sectional view of the staple drive assembly ofFIG. 50 showing the continued engagement between the cam members of thestaple pusher of FIG. 6 and the cam wedges of the actuation sled as theactuation sled continues to move in the direction of arrow A;

FIG. 52 is a side cross-sectional view of an end portion of an actuationmember according to an embodiment of the present disclosure;

FIG. 53 is a side cross-sectional view of an end portion of an actuationmember according to an alternate embodiment of the present disclosure;

FIG. 54 is a side cross-sectional view of an end portion of an actuationmember according to another embodiment of the present disclosure;

FIG. 55 is a side cross-sectional view of an end portion of an actuationmember according to a further embodiment of the present disclosure; and

FIG. 56 is a side cross-sectional view of an end portion of an actuationmember according to another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the presently disclosed staple drive assembly will now bedescribed in detail with reference to the drawings, in which likereference numerals designate identical or corresponding elements in eachof the several views. As used herein, the term “distal” refers to thatportion of the instrument, or component thereof which is further fromthe user while the term “proximal” refers to that portion of theinstrument or component thereof which is closer to the user.

A staple drive assembly 100, in accordance with one embodiment of thepresent disclosure, is illustrated in FIG. 1. Staple drive assembly 100includes an actuation sled 110 and at least one staple pusher 160.Actuation sled 110 includes a base 112, a first camming member 120, asecond camming member 140, and a guide member 150. First and secondcamming members 120, 140 include respective first or leading cam wedges122, 142 and respective second or trailing cam wedges 124, 144. In oneembodiment, staple drive assembly 100 is adapted for use in a surgicalstapler having at least two linear rows of staples such as an endoscopicor laparoscopic stapler.

An example of a surgical stapler having linear rows of staples isdisclosed in U.S. Pat. No. 6,669,073 to Milliman et al. currently ownedand assigned to United States Surgical, the entire contents of which areincorporated herein by reference. As illustrated in FIG. 2, the surgicalstapler is shown generally as 10. Surgical stapler 10 includes a triggerassembly 30, a body portion 12, a staple cartridge 40, and an anvilassembly 70. Trigger assembly 30 includes a pivotal trigger 32. Pivotalmovement of trigger 32 during an actuation sequence of trigger 32translates pivotal movement of trigger 32 into linear movement of adrive mechanism (not shown). The drive mechanism is operatively coupledto an actuation sled in staple cartridge 40 to translate linear movementof the drive mechanism to linear movement of the actuation sled. Stapler10 is movable such that a portion of body tissue (not shown) may bepositioned between anvil assembly 70 and staple cartridge 40. Actuationof stapler 10 moves anvil assembly 70 towards staple cartridge 40thereby grasping or retaining the portion of body tissue therebetween.In addition, once the portion of body tissue is grasped between anvilassembly 70 and staple cartridge 40, continued actuation of stapler 10discharges staples 50 (FIG. 3) through the portion of body tissue andagainst anvil assembly 70 to form completed staples 50. The presentlydisclosed staple drive assembly 100 may be incorporated into staplecartridge 40 of surgical stapler 10 disclosed in U.S. Pat. No.6,669,073. Alternately, staple drive assembly 100 may be incorporatedinto other known stapling devices including open-type surgical staplingdevices, such as the open surgical staplers shown and described U.S.Pat. Nos. 4,955,959; 4,978,049; 5,395,034; 5,630,541; 5,662,258;6,131,789 and D278,081 and other endoscopic or laparoscopic surgicalstapling devices, such as the endoscopic staplers shown and described inpublished U.S. Patent Applications 2004/0232195; 2004/0232197 and2004/0232199. While the present disclosure describes embodimentsinvolving an actuation sled, it also will be appreciated that the designcharacteristics and function of the sled camming members may beincorporated directly into cam bars or firing wedges, which in turn areconnected to the firing mechanism of the surgical stapling instrument.

FIG. 3 illustrates a staple cartridge 40′ including the staple driveassembly shown in FIG. 1. Staple cartridge 40′ includes a plurality offasteners or staples 50 and a corresponding number of staple pockets orretention slots 60. A tissue contacting surface 44 is defined by a topsurface of staple cartridge 40′. A guide channel 42 extendssubstantially the length of staple cartridge 40′ and is adapted forslidably receiving guide member 150 of actuation sled 110 as shown inFIG. 4. In FIG. 4, sled 110 is shown positioned at the proximal end ofcartridge 40′ with guide member 150 disposed in guide channel 42. Guidechannel 42 cooperates with guide member 150 for aligning and positioningactuation sled 110 in staple cartridge 40′ as it translateslongitudinally from a proximal end to a distal end of staple cartridge40′. Guide channel 42 may also facilitate passage of a knife blade (notshown) through cartridge 40′, such as by mounting a knife blade to guidemember 150.

In FIG. 5, a cross-sectional view taken along line 5-5 of FIG. 4,actuation sled 110 is shown disposed in the proximal end of staplecartridge 40′ in a first or ready position. In the ready position,actuation sled 110 is capable of translating distally through staplecartridge 40′ (i.e. in the direction indicated by arrow A) andsequentially engaging staple pushers 160 (FIG. 3) as discussed in detailhereinbelow. Actuation sled 110 is translatable along a longitudinalaxis of staple cartridge 40′ from its ready position to a second or endposition located in a distal portion of staple cartridge 40′.

Turning now to FIGS. 6-10, several views of one embodiment of staplepusher 160 are illustrated. Each staple pusher 160 includes a first cammember 162, a second cam member 164, and at least one prong or pusherplate 166. In one embodiment, each staple pusher 160 includes threepusher plates 166 that are laterally and longitudinally spaced apartfrom each other. Generally, first and second cam members 162, 164 andpusher plates 166 lie in a plane parallel to a longitudinal axis ofstaple cartridge 40′. As illustrated in FIGS. 6 and 7, each pusher plate166 includes a leading edge 166 a and a trailing edge 166 b. In oneembodiment, pusher plates 166 may be longitudinally spaced apart orstaggered such that the longitudinal spacing between leading edges 166 aof adjacent pusher plates 166 is about two-thirds the length ofretention slot 60 or about two-thirds the length of an adjacent pusherplate 166. Further still, each pusher plate 166 includes a top surface166 c that is adapted for releasably engaging a backspan 52 of a staple50 (see FIG. 1). Each retention slot 60 of staple cartridge 40′ isconfigured for releasably receiving a staple 50 and a pusher plate 166(see FIG. 3). Additionally, each staple includes two legs 54.

As previously discussed, staple pusher 160 includes prongs or pusherplates 166 that are laterally and longitudinally spaced apart as well asfirst and second cam members 162, 164 interposed between adjacent pusherplates 166. More specifically, as discussed hereinabove, in oneembodiment of the present disclosure, each staple pusher 160 includes aplurality of pusher plates 166 that are substantially parallel to alongitudinal axis of staple cartridge 40′ and parallel to a centerlineCL of each staple pusher 160 (FIG. 8). Additionally, first and secondcam members 162, 164 are also substantially parallel to centerline CL(FIG. 8). Staple pusher 160, as viewed from left to right in FIG. 8(i.e. distal to proximal), includes an inboard pusher plate 166 that ismost distal along centerline CL. A middle pusher plate 166 is laterallyspaced apart from inboard pusher plate 166 and is axially offset in theproximal direction from inboard pusher plate 166. An outboard pusherplate 166 is laterally spaced apart from middle pusher plate 166 and isaxially offset in the proximal direction from middle pusher plate 166.Further still, first cam member 162 is disposed between inboard pusherplate 166 and middle pusher plate 166 while second cam member 164 isdisposed between middle pusher plate 166 and outboard pusher plate 166.Configured thusly, staple pusher 160 has an arrangement where pusherplates 166 are longitudinally staggered from a distal portion of staplepusher 160 to a proximal portion of staple pusher 160 as seen in FIG. 8.

First and second cam members 162, 164 include respective first andsecond cam surfaces 162 a, 162 b and 164 a, 164 b (FIGS. 9 and 10). Atthe intersection of first and second cam surfaces 162 a, 162 b and 164a, 164 b are respective transition points 162 c, 164 c. A plane T (FIG.10) extending through transition points 162 c, 164 c is parallel torespective tops 163, 165 of cam members 162, 164. In one embodiment,first cam surfaces 162 a, 164 a define a first engagement or receivingangle with respect to tops 163, 165 of respective first and second cammembers 162, 164. Second cam surfaces 162 b, 164 b define a secondengagement or receiving angle with respect to plane T. First and secondreceiving angles are complementary to respective first and second driveangles of camming members 120, 140 of actuation sled 110 as discussed indetail hereinbelow. In one embodiment, the first receiving angles may bein a range of about 15° to about 55° while the second receiving anglesmay be in a range of about 5° to about 35°. In another embodiment, thefirst receiving angles may be in a range of about 25° to about 45° whilethe second receiving angles may be in a range of about 10° to about 30°.In a further embodiment, first receiving angles may be in a range ofabout 30° to about 40° while second receiving angles may be in a rangeof about 15° to about 25°.

Alternate embodiments of the presently disclosed staple pusher areillustrated in FIGS. 26-29 and discussed in detail hereinbelow.Initially referring to FIGS. 26-27, staple pusher 260 is illustrated andincludes the same or substantially similar components to staple pusher160. Each staple pusher 260 includes a first cam member 262, a secondcam member 264, and a single prong or pusher plate 266. Generally, firstand second cam members 262, 264 and pusher plates 266 lie in a planeparallel to a longitudinal axis of staple cartridge 40′. As illustratedin FIGS. 26 and 27, each pusher plate 266 includes a leading edge 266 aand a trailing edge 266 b. Further still, each pusher plate 266 includesa top surface 266 c that is adapted for releasably engaging a backspan52 of a staple 50 (see FIG. 1). Each retention slot 60 of staplecartridge 40′ is configured for releasably receiving a staple 50 and apusher plate 266 (see FIG. 3).

Staple pusher 260 includes a prong or a pusher plate 266 that separatesfirst and second cam members 262, 264. More specifically, each staplepusher 260 includes a single pusher plate 266 that is substantiallyparallel to a longitudinal axis of staple cartridge 40′ and parallel toa centerline CL of each staple pusher 260 (FIG. 27). Additionally, firstand second cam members 262, 264 are also substantially parallel tocenterline CL (FIG. 27).

First and second cam members 262, 264 include respective first andsecond cam surfaces 262 a, 262 b and 264 a, 264 b (FIG. 26). At theintersection of first and second cam surfaces 262 a, 262 b and 264 a,264 b are respective transition points 262 c, 264 c. A plane T (FIG. 26)extending through transition points 262 c, 264 c is parallel torespective tops 263, 265. In one embodiment, first cam surfaces 262 a,264 a define a first engagement or receiving angle with respect to tops263, 265 of respective first and second cam members 262, 264. Second camsurfaces 262 b, 264 b define a second engagement or receiving angle withrespect to plane T. First and second receiving angles are complementaryto respective first and second drive angles of camming members 120, 140as discussed in detail hereinbelow. In one embodiment, the firstreceiving angles may be in a range of about 15° to about 55° while thesecond receiving angles may be in a range of about 5° to about 35°. Inanother embodiment, the first receiving angles may be in a range ofabout 25° to about 45° while the second receiving angles may be in arange of about 10° to about 30°. In a further embodiment, firstreceiving angles may be in a range of about 30° to about 40° whilesecond receiving angles may be in a range of about 15° to about 25°.

Referring now to FIGS. 28 and 29, another embodiment of the staplepusher of the present disclosure is shown and referenced as 360. Eachstaple pusher 360 includes a first cam member 362, a second cam member364, and two prongs or pusher plates 366 that are laterally andlongitudinally spaced apart from each other. Generally, first and secondcam members 362, 364 and pusher plates 366 lie in a plane parallel to alongitudinal axis of staple cartridge 40′. As illustrated in FIGS. 28and 29, each pusher plate 366 includes a leading edge 366 a and atrailing edge 366 b. Pusher plates 366 may be longitudinally spacedapart or staggered such that the longitudinal spacing between leadingedges 366 a of adjacent pusher plates 366 is about two-thirds the lengthof retention slot 60 or about two-thirds the length of pusher plate 366.Further still, each pusher plate 366 includes a top surface 366 c thatis adapted for releasably engaging a backspan 52 of a staple 50 (seeFIG. 1). Each retention slot 60 of staple cartridge 40′ is configuredfor releasably receiving a staple 50 and a pusher plate 366 (see FIG.3).

First and second cam members 362, 364 include respective first andsecond cam surfaces 362 a, 362 b and 364 a, 364 b (FIGS. 28 and 29). Atthe intersection of first and second cam surfaces 362 a, 362 b and 364a, 364 b are respective transition points 362 c, 364 c. A plane T (FIG.28) extending through transition points 362 c, 364 c is parallel torespective tops 363, 365. In one embodiment, first cam surfaces 362 a,364 a define a first engagement or receiving angle with respect to tops363, 365 of respective first and second cam members 362, 364. Second camsurfaces 362 b, 364 b define a second engagement or receiving angle withrespect to plane T. First and second receiving angles are complementaryto respective first and second drive angles of camming members 120, 140as discussed in detail hereinbelow. In one embodiment, the firstreceiving angles may be in a range of about 15° to about 55° while thesecond receiving angles may be in a range of about 5° to about 35°. Inanother embodiment, the first receiving angles may be in a range ofabout 25° to about 45° while the second receiving angles may be in arange of about 10° to about 30°. In a further embodiment, firstreceiving angles may be in a range of about 30° to about 40° whilesecond receiving angles may be in a range of about 15° to about 25°.

With reference to FIGS. 11-15, several views of one embodiment ofactuation sled 110 are shown. First and second camming members 120, 140each include a first or leading cam wedge 122, 142, respectively, thatis laterally and longitudinally spaced apart from a second or trailingcam wedge 124, 144, respectively. The lateral and longitudinal offsetdistances of each pair of camming wedges substantially corresponds tothe lateral and longitudinal offset distances between corresponding cammembers 162, 164. First cam wedges 122, 142 are laterally andlongitudinally spaced from second cam wedges 124, 144, respectively, bya substantially identical amount such that first and second cammingmembers 120, 140 are symmetrical about a central longitudinal axis ofactuation sled 110. Leading cam wedges 122, 142 include respective firstand second drive faces 122 a, 122 b, 142 a, and 142 b. First drive faces122 a, 142 a form first drive angles on camming members 120, 140 withrespect to base 112 of actuation sled 110. At the intersection of firstand second drive faces 122 a, 142 a and 122 b, 142 b are respectivetransition points 123, 143. A plane X extending through transitionpoints 123, 143 is substantially parallel to base 112. Second drivefaces 122 b, 142 b form respective second drive angles on cammingmembers 120, 140 with respect to plane X. Plane X is also substantiallyparallel to tissue contacting surface 44 of staple cartridge 40′.

Similarly, trailing cam wedges 124, 144 include respective first andsecond drive faces 124 a, 124 b, 144 a, and 144 b. First drive faces 124a, 144 a form first drive angles on camming members 120, 140 withrespect to base 112 (FIG. 5) of actuation sled 110. At the intersectionof first and second drive faces 124 a, 124 b and 144 a, 144 b arerespective transition points 125, 145. Plane X extends throughtransition points 125, 145 and is substantially parallel to base 112.Second drive faces 124 b, 144 b form respective second drive angles oncamming members 120, 140 with respect to plane X. In one embodiment,first drive angles may be in a range of about 15° to about 55° whilesecond drive angles may be in a range of about 5° to about 35°. Inanother embodiment, first drive angles may be in a range of about 25° toabout 45° while second drive angles may be in a range of about 10° toabout 30°. In a further embodiment, first drive angles may be in a rangeof about 30° to about 40° while second drive angles may be in a range ofabout 15° to about 25°.

Interaction between actuation sled 110 and staple pusher 160 of stapledrive assembly 100 is shown in FIGS. 16-18 and discussed in detailhereinafter. Initially, as illustrated in FIG. 16, actuation sled 110translates distally through staple cartridge 40′ in the directionindicated by arrow A (see also FIG. 5) causing first drive face 122 a toslidably engage first cam surface 162 a and urge staple pusher 160 fromits first or rest position in a generally vertical direction asindicated by arrow B. Because the lateral and longitudinal offsetdistances of wedges 122, 124 correspond to the lateral and longitudinaloffset distances between cam wedges 162, 164, first drive face 124 asubstantially simultaneously slidably engages first cam surface 164 athereby urging staple pusher 160 in a generally vertical direction asindicated by arrow B. Since cam surfaces 162 a and 164 a arelongitudinally offset, staple pusher 160 is driven in a controlled andbalanced manner and any tendency of staple pusher 160 to tilt or rotatecounterclockwise (as viewed in FIGS. 16-17) is minimized as staplepusher 160 is driven through retainer slot 60. First drive faces 122 a,124 a and respective first cam surfaces 162 a, 164 a have complementaryangles that maximize translation of longitudinal motion of actuationsled 110 to vertical motion of staple pusher 160.

Referring now to FIG. 17, continued distal movement of actuation sled110 further urges staple pusher 160 generally vertically to anintermediate position, such that second drive faces 122 b, 124 bslidably engage respective second cam surfaces 162 b, 164 b while firstdrive faces 122 a, 124 a substantially simultaneously disengage fromrespective first cam surfaces 162 a, 164 a. Similarly, second drivefaces 122 b, 124 b and respective second cam surfaces 162 b, 164 b havecomplementary angles to maximize translation of longitudinal motion ofactuation sled 110 to vertical motion of staple pusher 160. Thecorresponding lateral and longitudinal offset of second drive faces 122b, 124 b and respective second cam surfaces 162 b, 164 b continue tocontrol the advancement of staple pusher 160 so as to minimize anytendency of staple pusher 160 to tilt or rotate in a counterclockwisedirection as viewed in FIGS. 16-17. Continuing distal movement ofactuation sled 110 continues to urge staple pusher 160 vertically to itssecond or end position immediately prior to the disengagement betweensecond drive faces 122 b, 124 b and respective second cam surfaces 162b, 164 b.

Since the interaction between second camming member 140 and staplepusher 160 is substantially identical to the intersection of firstcamming member 120 and pusher 160, the intersection of second cammingmember 140 and staple pusher 160 will not be described in detail herein.

Longitudinal motion of actuation sled 110 in the direction indicated byarrow A results in first and second camming members 120, 140 slidablyengaging staple pushers 160 as shown in FIGS. 16-18. Sliding engagementbetween leading cam wedges 122, 142 and first cam members 162 incooperation with the substantially simultaneous engagement betweentrailing cam wedges 124, 144 and second cam members 164 improve thelongitudinal stability of the staple pushers 160 during vertical motionas follows. Leading cam wedges 122, 142 are longitudinally spaced apartfrom trailing cam wedges 124, 144 by a predetermined amount. Sincerespective first and second cam members 162, 164 are longitudinallyspaced apart by a comparable, but complementary amount, longitudinalmovement of actuation sled 110 results in the substantiallysimultaneous, but offset engagement of leading cam wedges 122, 124 andtrailing cam wedges 124, 144 with respective first and second cammembers 162, 164 thereby transferring the longitudinal movement ofactuation sled 110 to vertical movement of staple pusher 160 atlongitudinally spaced apart impact points. By transferring longitudinalmovement of actuation sled 110 to each staple pusher 160 at twolongitudinally spaced apart impact points, substantially balancedvertical movement of each staple pusher 160 is achieved. Since there istwo point contact between first and second camming members 120, 140 andrespective first and second cam members 162, 164 throughout the verticaltravel of each staple pusher 160, pivoting or tilting of each staplepusher 160 is minimized due to the two-point contact arrangement.Minimizing pivoting or tilting of each staple pusher 160 during verticaltravel further minimizes pivoting or tilting of each staple 50 as eachstaple 50 is driven vertically in its respective retention slot 60. Thisprovides more precise contact of a staple with an anvil pocket (notshown) and thus, improved staple formation.

In addition, the lateral offset between cam wedges 122, 124 of firstcamming member 120 and cam wedges 142, 144 of second camming member 140inhibits “rocking” of staple pusher 160. “Rocking” of staple pushers mayoccur when the lifting force applied to the staple pusher by theactuation sled is not balanced creating a tendency for the staple pusherto “rock” in a direction that is transverse to the movement of theactuation sled. This “rocking” movement may cause misalignment of thestaple during a firing sequence resulting in non-uniform stapleformation. In extreme circumstances, “rocking” may cause a “front jump”staple formation wherein the rear leg of a staple exits the staplecartridge at an angle and enters the anvil pocket at the same locationas the front leg of the same staple. By providing actuation sled 110with laterally offset cam wedges, actuation sled 110 contacts staplepusher 160 at two laterally spaced contact points substantiallysimultaneously, thereby imparting a lifting force to staple pusher 160that is substantially balanced between first and second cam members 162,164. Therefore, engagement of actuation sled 110 with staple pusher 160results in substantially even vertical motion of staple pusher 160 andinhibits “rocking” of staple pusher 160 and inhibits front jump stapleformation.

Further still, as previously discussed, each cam wedge (122, 124, 142,144) defines a plurality of receiving angles that are complementary todrive angles defined by cam members 162, 164. When the first drive angleis greater than the second drive angle, single point contact between thestaple pusher and the cam wedge may occur. Instability of the staplepusher due to such single point contact can also result in tilting orrotation of the staple pusher during firing. Such instability is mostlikely to occur as the staple pusher transitions from contacting onedrive surface to the other drive surface. As described above, unbalancedvertical movement of staple pusher 160 can cause staple pusher 160 totravel vertically at an angle such that top surfaces 166 c (FIG. 1) ofstaple pusher 160 are not substantially parallel to tissue contactingsurface 44 or backspan 52 of staple 50 (FIG. 3). This may lead toimproperly formed staples, misalignment of the staples with the anvilpockets, or misalignment of the staples with the retention slots. Byproviding different angles on each cam wedge, an angular differential isdefined wherein the angular differential minimized “rotation” of staplepusher 160.

Interaction between actuation sled 110 and staple pushers 260, 360 issubstantially similar to the interaction described hereinabove betweenactuation sled 110 and staple pusher 160 and will not be discussed indetail. It is sufficient to note that staple pushers 260, 360 may befreely substituted for staple pusher 160.

Referring now to FIGS. 19-25, another embodiment of the presentlydisclosed staple drive assembly 200 is illustrated (FIGS. 24-25). Stapledrive assembly 200 includes an actuation sled 210 (FIGS. 19-23) and atleast one staple pusher 160 (FIGS. 6-10). Actuation sled 210 is adaptedand configured for use in staple cartridge 40′ as an alternative foractuation sled 110. As seen in FIGS. 19-23, actuation sled 210 includesa first camming member 220, a second camming member 240, and a guidemember 250. First and second camming members 220, 240 include respectivefirst or leading cam wedges 222, 242 and respective second or trailingcam wedges 224, 244.

Similar to actuation sled 110, leading cam wedges 222, 242 of actuationsled 210 include first drive faces 222 a, 242 a and second drive faces222 b, 242 b. Interposed between first drive faces 222 a, 242 a andsecond drive faces 222 b, 242 b are respective first and secondtransition points 223, 243. First drive faces 222 a, 242 a extendproximally from a distal point 214 both longitudinally and verticallythereby forming a first drive angle with respect to base 212. Trailingcam wedges 224, 244 are longitudinally spaced apart from leading camwedges 222, 242 by a predetermined distance. First drive faces 224 a,244 a of trailing cam wedges 224, 244 extend both longitudinally andvertically in a proximal direction from respective origin points 214 a,214 b to form the first drive angle with respect to base 212. A plane X′extending through transition points 223, 243 (FIG. 23) of leading camwedges 222, 242 is parallel to base 212. Second drive faces 222 b, 242 bform respective second drive angles with respect to plane X′.Additionally, plane X′ extends through transition points 225, 245 (FIG.23) of trailing cam wedges 224, 244 and is substantially parallel tobase 212. Plane X′ is also substantially parallel to tissue contactingsurface 44 of staple cartridge 40′. Second drive faces 224 b, 244 b formrespective second drive angles with respect to plane X′. In oneembodiment, first drive angles may be in a range of about 5° to about35° while second drive angles may be in a range of about 20° to about55°. In another embodiment, first drive angles may be in a range ofabout 10° to about 30° while second drive angles may be in a range ofabout 25° to about 45°. In a further embodiment, first drive angles maybe in a range of about 15° to about 25° while the second drive anglesmay be in a range of about 30° to about 40°. By providing actuation sled210 with first drive faces 222 a, 242 a having a flatter initialengaging surface having a lower angle relative to a plane parallel tobase 212, interaction between actuation sled 210 and each staple pusher160 is more controllable. As actuation sled 210 translates throughstaple cartridge 40′ and interacts with each staple pusher as discussedabove, actuation sled 210 gradually and controllably urges each staplepusher 160 vertically as actuation sled 210 translates through staplecartridge 40′.

In staple drive assembly 200, the interaction between actuation sled 210and staple pusher 160 is illustrated in FIGS. 24-25 and discussed indetail hereinafter. As actuation sled 210 moves distally through staplecartridge 40′ (see FIG. 5) in a generally horizontal direction asindicated by arrow A, first drive faces 222 a, 224 a contact respectivesecond cam surfaces 162 b, 164 b and urge staple pusher 160 in agenerally vertical direction as indicated by arrow B from its first orrest position. Since the first drive angle is defined by first drivefaces 222 a, 224 a and is complementary to the second receiving angledefined by second cam surfaces 162 b, 164 b, horizontal movement ofactuation sled 210 in direction A causes vertical movement of staplepusher 160 in direction B.

As actuation sled 210 continues to move in the direction of arrow A,second drive faces 222 b, 224 b engage respective first cam surfaces 162a, 164 a and first drive faces 222 a, 224 a remain engaged with theirrespective second cam surfaces 162 b, 164 b, thereby providingadditionally longitudinal and vertical stability of staple pusher 160.After actuation sled 210 moves a predetermined distance in the directionof arrow A, first drive faces 222 a, 224 a disengage from theirrespective second cam surfaces 162 b, 164 b while second drive faces 222b, 224 b remain engaged with their respective first cam surfaces 162 a,164 a. The second drive angle defined by second drive faces 222 b, 224 bis complementary to the first receiving angle defined by first camsurfaces 162 a, 164 a further urging staple pusher 160 in the directionof arrow B through an intermediate position. Continuing distal movementof actuation sled 210 continues to urge staple pusher 160 vertically toits second or end position immediately prior to the disengagementbetween second drive faces 222 b, 224 b and respective second camsurfaces 162 a, 164 a. A cam wedge having a first drive angle which isless than the second drive angle creates multiple contact points betweenthe cam wedge and the staple pusher as the staple pusher transitionsfrom contacting the first drive surface to contacting the second drivesurface, thereby further enhancing the stability of the staple pusherduring firing. In addition, providing a first drive angle less than thesecond drive angle minimizes misalignment since there is additionalsupport for the staple pusher during its vertical movement.

Since the interaction between second camming member 240 and staplepusher 160 is substantially identical to the interaction between firstcamming member 220 and staple pusher 160, the interaction between secondcamming member 240 and staple pusher 160 will not be described infurther detail herein. It is sufficient to note that staple pushers 260,360 may be freely substituted for staple pusher 160.

The sliding engagement between leading cam wedges 222, 242 and first cammembers 162 in cooperation with the substantially simultaneousengagement between trailing cam wedges 224, 244 and second cam members164 is substantially similar to that discussed hereinabove for stapledrive assembly 100 and improves the longitudinal stability of the staplepushers 160 during vertical motion.

Interaction between actuation sled 210 and staple pushers 260, 360 issubstantially similar to the interaction described hereinabove betweenactuation sled 210 and staple pusher 160 and will not be discussed indetail.

Referring now to FIGS. 30-36, another embodiment of the presentlydisclosed staple drive assembly 300 is illustrated (FIGS. 35-36). Stapledrive assembly 300 includes an actuation sled 310 (FIGS. 30-34) and atleast one staple pusher 160 (FIGS. 6-10). Actuation sled 310 is adaptedand configured for use in staple cartridge 40′ as an alternative foractuation sled 110 or actuation sled 210.

As shown in FIGS. 30-34, actuation sled 310 includes a first cammingmember 320, a second camming member 340, and a guide member 350. Firstand second camming members 320, 340 include respective first or leadingcam wedges 322, 342 and respective second or trailing cam wedges 324,344.

Similar to actuation sleds 110 and 210, trailing cam wedges 324, 344 arelaterally and longitudinally spaced apart from leading cam wedges 322,342 by a predetermined distance. Leading cam wedges 322, 342 includeleading drive faces 322 a, 342 a while trailing cam wedges 324, 344include trailing drive faces 324 a, 344 a. Drive faces 324 a, 344 a oftrailing cam wedges 324, 344 extend both longitudinally and verticallyin a proximal direction from respective origin points 314 a, 314 b.Drive faces 322 a, 342 a of leading cam wedges also extend bothlongitudinally and vertically in a proximal direction from respectiveorigin points 316 a, 316 b. Drive faces 322 a, 342 a, 324 a, 344 a eachform a drive angle with respect to base 312 wherein the drive angle issubstantially identical for drive faces 322 a, 342 a, 324 a, 344 a. Inone embodiment, the drive angle may be in a range of about 15° to about25°. In another embodiment, the drive angle may be in a range of about10° to about 30°. In a further embodiment, the drive angle may be in arange of about 5° to about 35°.

In staple drive assembly 300, the interaction between actuation sled 310and staple pusher 160 is illustrated in FIGS. 35-36 and discussed indetail hereinafter. As actuation sled 310 moves distally through staplecartridge 40′ (see FIG. 5) in a generally horizontal direction asindicated by arrow A, drive faces 322 a, 324 a engage cam surfaces 162,164 of staple pusher 160 and urge staple pusher 160 in a generallyvertical direction as indicated by arrow B from its first or restposition. As in previous embodiments, cam surfaces 162, 164 definereceiving angles that are complementary to the drive angle formed bydrive faces 322 a, 324 a. Cam surfaces 162, 164 are laterally andlongitudinally spaced apart so that the spacing of cam surfaces 162, 164corresponds to the lateral and longitudinal spaced of the cam wedgedrive faces. As actuation sled 310 moves distally through staplecartridge 40′, cam surfaces 162, 164 of staple pusher 160 maintain theirengagement with drive faces 322 a, 324 a of actuation sled 310. As willbe appreciated, the lateral and longitudinal spacing of the cam wedgesand cam surfaces provides improved stability to the staple pusher duringfiring, as described above, albeit without the varied drive angles ofthe drive surfaces.

Since the interaction between second camming member 340 and staplepusher 160 is substantially identical to the interaction between firstcamming member 320 and staple pusher 160, the interaction between secondcamming member 340 and staple pusher 160 will not be described infurther detail herein. It is sufficient to note that staple pushers 260,360 may be freely substituted for staple pusher 160.

The sliding engagement between leading cam wedges 322, 342 and first cammembers 162 in cooperation with the substantially simultaneousengagement between trailing cam wedges 324, 344 and second cam members164 is substantially similar to that discussed hereinabove for stapledrive assembly 100, 200 and improves the longitudinal stability of thestaple pushers 160 during vertical motion.

Interaction between actuation sled 310 and staple pushers 260, 360 issubstantially similar to the interaction described hereinabove betweenactuation sled 310 and staple pusher 160 and will not be discussed indetail.

Referring now to FIGS. 37-44 another embodiment of the presentlydisclosed staple drive assembly 400 is illustrated (FIGS. 43-44). Stapledrive assembly 400 includes an actuation sled 410 (FIGS. 37-41) and atleast one staple pusher 460 (FIGS. 42A-42B). Actuation sled 410 isadapted and configured for use in staple cartridge 40′ (FIG. 4).

As shown in FIGS. 42A-B, staple pusher 460 includes a first cam member462, a second cam member 464, and at least one prong or pusher plate466. In one embodiment, staple pusher 460 includes three pusher plates466 that are laterally spaced apart from each other by first and secondcam members 462, 464. Generally, first and second cam members 462, 464and pusher plates 466 lie in a plane parallel to the longitudinal axisof staple cartridge 40′. Each pusher plate 466 includes a leading edge466 a, a trailing edge 466 b, and a top surface 466 c. In oneembodiment, one pusher plate 466 may be longitudinally spaced such thatpusher plates 466 are in a staggered orientation with respect to eachother such that the two outside pusher plates are laterally aligned witheach other, but the middle pusher plate is displaced from lateralalignment with the side pusher plates. An example of a suitable staplepusher is disclosed in U.S. Pat. No. 4,978,049 to Green, currently ownedby Tyco Healthcare Group LP, the entire contents of which areincorporated herein by reference.

First and second cam members 462, 464 include respective cam surfaces462 aa, 464 a (FIG. 42A). In one embodiment, cam surfaces 462 a, 464 adefine an engagement or receiving angle with respect to tops 463, 465 ofrespective first and second cam members 462, 464. The receiving angle iscomplementary to a first drive angle of camming members 420, 440 ofactuation sled 410 as discussed in detail hereinbelow. In oneembodiment, the receiving angle may be in a range of about 15° to about25°. In another embodiment, the receiving angle may be in a range ofabout 17° to about 23°. In a further embodiment, the receiving angle maybe in a range of about 19° to about 21°.

With reference to FIGS. 37-41, actuation sled 410 of staple driveassembly 400 includes first and second camming members 420, 440 eachhaving a first cam wedge 422, 442, respectively, that is laterallyspaced apart from a second cam wedge 424, 444, respectively. First camwedges 422, 442 are laterally spaced from second cam wedges 424, 444,respectively, by a substantially identical amount such that first andsecond camming members 420, 440 are substantially symmetrical about acentral longitudinal axis of actuation sled 410. Each cam wedge 422,424, 442, 444 includes a plurality of drive faces as shown in FIGS.37-38 where each of the respective drive faces are indicated byreference characters “a-d.” A plane Y extends through the intersectionbetween drive faces “a” and “b.” Plane Y is substantially parallel to abase 412 and to tissue contacting surface 44 of staple cartridge 40′(see FIG. 3). First cam wedge 422 will be discussed in detail below toillustrate the relationship between the drive faces with cam wedges 424,442, and 444 having substantially identical relationships.

First cam wedge 422 of cam member 420 includes first through fourthdrive faces 422 a, 422 b, 422 c, and 422 d as shown in FIG. 41. Firstdrive face 422 a defines a first angle with respect to base 412 whilesecond drive face 422 b defines a second drive angle with respect toplane Y. In addition, the slope of drive faces 422 c and 422 d aresubstantially identical to the slopes of drive faces 422 a and 422 brespectively. In one embodiment of actuation sled 410, the first andthird drive angles (i.e. defined by drive faces 422 a, 442 c) may be ina range of about 15° to about 25°. In another embodiment, the first andthird drive angles may be in a range of about 17° to about 23°. In afurther embodiment, the first and third drive angles may be in a rangeof about 19° to about 21°. The second drive angle (i.e. defined by drivefaces 422 b, 422 d) may be in a range of about 26° to 36°. In anotherembodiment, the second drive angle may be in a range of about 28° to34°. In a further embodiment, the second drive angle may be in a rangeof about 30° to about 32°.

Interaction between actuation sled 410 and staple pusher 460 of stapledrive assembly 400 is shown in FIGS. 43-44 and discussed in detailhereinafter. Initially, as illustrated in FIG. 43, actuation sled 410translates distally through staple cartridge 40′ in the directionindicated by arrow A causing cam wedges 422, 424 of first cam member 420to slidably engage staple pusher 460. Specifically, first drive faces422 a, 424 a substantially simultaneously slidably engage respective camsurfaces 462 a, 464 a and urge staple pusher 460 from its first or restposition in a generally vertical direction as indicated by arrow B. Inone embodiment of staple drive assembly 400, the first and third driveangles of cam wedges 422, 424, 442, and 444 are complementary to thefirst receiving angle of cam surfaces 462 a, 464 a. As actuation sled410 moves distally with drive faces 422 a, 424 a in slidable engagementwith respective cam surfaces 462 a, 464 a (i.e. engaging the first driveangle), top surfaces 466 c of pusher plates 466 engage backspan 52 ofstaple 50 and urge staple 50 in a substantially vertical direction andengages tissue in contact with tissue contacting surface 44. Asactuation sled 410 continues distal movement, cam surfaces 462 a, 464 aslidably engage respective second drive faces 422 b, 424 b continuing tourge staple 50 vertically. As illustrated in FIG. 44, continued distaltranslation of actuation sled 410 causes cam surfaces 462 a, 464 a toslidably engage drive faces 422 c, 424 c (i.e. engaging the third driveangle), thereby moving legs 54 of staple 50 into engagement with anvilassembly 70 to form completed staples 50. By providing first and thirddrive angles of respective first drive faces 422 a, 424 a, and thirddrive faces 422 c, 424 c that are complementary to the receiving anglesof cam surfaces 462 a, 464 a, the interaction between the distalmovement of actuation sled 410 and staple pusher 460 may reduce thefiring force necessary to fire staples 50. In addition to matching thedrive angles and the receiving angles, first drive faces 422 a, 424 aare spaced apart from third drive faces 422 c, 424 c by a predetermineddistance thereby further minimizing kicking of staple pusher 460 asstaple 50 engages tissue and anvil assembly 70, respectively.

Since the interaction between second camming member 440 and staplepusher 460 is substantially identical to the interaction of firstcamming member 420 and pusher 460, the interaction of second cammingmember 440 and staple pusher 460 will not be described in detail herein.

In addition, another embodiment of the staple drive assembly isillustrated in FIGS. 45-51 and referenced generally as 500 (FIGS.50-51). Staple drive assembly 500 includes actuation sled 510 (FIGS.45-49) having first and second camming members 520, 540 each having afirst cam wedge 522, 542, respectively, that is laterally spaced apartfrom a second cam wedge 524, 544, respectively. First cam wedges 522,542 are laterally spaced from second cam wedges 524, 544, respectively,by a substantially identical amount such that first and second cammingmembers 520, 540 are substantially symmetrical about a centrallongitudinal axis of actuation sled 510. Each cam wedge 522, 524, 542,544 includes a plurality of drive faces as shown in FIGS. 45-46 whereeach of the respective drive faces are indicated by reference characters“a-d.” A plane Y extends through the intersection between drive faces“a” and “b.” Plane Y is substantially parallel to a base 512 and totissue contacting surface 44 of staple cartridge 40′ (FIG. 3). Inaddition, first cam wedges 522, 542 are longitudinally spaced fromsecond cam wedges 524, 544. First cam wedge 522 will be discussed indetail below to illustrate the relationship between the drive faces withcam wedges 524, 542, and 544 having substantially identicalrelationships.

First cam wedge 522 of cam member 520 includes first through fourthdrive faces 522 a, 522 b, 522 c, and 522 d as shown in FIG. 49. Firstdrive face 522 a defines a first angle with respect to base 512 whilesecond drive face 522 b defines a second drive angle with respect toplane Y. In addition, the slope of drive faces 522 c and 522 d aresubstantially identical to the slopes of drive faces 522 a and 522 brespectively. In one embodiment of actuation sled 510, the first andthird drive angles (i.e. defined by drive faces 522 a, 542 c) may be ina range of about 15° to about 55°. In another embodiment, the first andthird drive angles may be in a range of about 25° to about 45°. In afurther embodiment, the first and third drive angles may be in a rangeof about 30° to about 40°. The second drive angle (i.e. defined by drivefaces 522 b, 522 d) may be in a range of about 5° to 35°. In anotherembodiment, the second drive angle may be in a range of about 10° to30°. In a further embodiment, the second drive angle may be in a rangeof about 15° to about 25°.

Interaction between actuation sled 510 and staple pusher 160 (FIG. 6) ofstaple drive assembly 500 is shown in FIGS. 50-51 and discussed indetail hereinafter. Initially, as illustrated in FIG. 50, actuation sled510 translates distally through staple cartridge 40′ in the directionindicated by arrow A causing first drive face 522 a to slidably engagefirst cam surface 162 a and urge staple pusher 160 from its first orrest position in a generally vertical direction as indicated by arrow B.Substantially simultaneously, first drive face 524 a slidably engagesfirst cam surface 164 a thereby urging staple pusher 160 in a generallyvertical direction as indicated by arrow B. Since cam surfaces 162 a,164 a and first drive faces 522 a, 524 a are longitudinally offset,staple pusher 160 is driven in a balanced manner to minimize tipping ortilting of staple pusher 160 as it is driven through retainer slot 60.First drive faces 522 a, 524 a and respective first cam surfaces 162 a,164 a have complementary angles that maximize translation oflongitudinal motion of actuation sled 510 to vertical motion of staplepusher 160.

Referring now to FIG. 51, continued distal movement of actuation sled510 further urges staple pusher 160 generally vertically to anintermediate position, such that second drive faces 522 b, 524 bslidably engage respective second cam surfaces 162 b, 164 b while firstdrive faces 522 a, 524 a substantially simultaneously disengage fromrespective first cam surfaces 162 a, 164 a. Similarly, second drivefaces 522 b, 524 b and respective second cam surfaces 162 b, 164 b havecomplementary angles to maximize translation of longitudinal motion ofactuation sled 510 to vertical motion of staple pusher 160. Continuingdistal movement of actuation sled 510 continues to urge staple pusher160 vertically to its second or end position immediately prior to thedisengagement between second drive faces 522 b, 524 b and respectivesecond cam surfaces 162 b, 164 b.

Since the interaction between second camming member 540 and staplepusher 160 is substantially identical to the intersection of firstcamming member 520 and pusher 160, the intersection of second cammingmember 540 and staple pusher 160 will not be described in detail herein.

Longitudinal motion of actuation sled 510 in the direction indicated byarrow A results in first and second camming members 520, 540 slidablyengaging staple pushers 160 as shown in FIGS. 50-51. Sliding engagementbetween leading cam wedges 522, 542 and second cam members 164 incooperation with the substantially simultaneous engagement betweentrailing cam wedges 524, 544 and first cam members 162 improve thelongitudinal stability of the staple pushers 160 during vertical motionas follows. Leading cam wedges 522, 542 are longitudinally spaced apartfrom trailing cam wedges 524, 544 by a predetermined amount. Sincerespective first and second cam members 162, 164 are longitudinallyspaced apart by a comparable, but complementary amount, longitudinalmovement of actuation sled 510 results in the substantially simultaneousengagement of leading cam wedges 522, 524 and trailing cam wedges 524,544 with respective first and second cam members 162, 164 therebytransferring the longitudinal movement of actuation sled 510 to verticalmovement of staple pusher 160 at longitudinally spaced apart impactpoints. By transferring longitudinal movement of actuation sled 510 toeach staple pusher 160 at two longitudinally spaced apart impact points,substantially balanced vertical movement of each staple pusher 160 isachieved. Since there is two point contact between first and secondcamming members 520, 540 and respective first and second cam members162, 164 throughout the vertical travel of each staple pusher 160,pivoting or tilting of each staple pusher 160 is minimized due to thetwo-point contact arrangement. Minimizing pivoting or tilting of eachstaple pusher 160 during vertical travel further minimizes pivoting ortilting of each staple 50 as each staple 50 is driven vertically in itsrespective retention slot 60. This provides more precise contact of astaple with an anvil pocket (not shown) and thus, improved stapleformation.

Interaction between actuation sled 510 and staple pushers 260, 360 issubstantially similar to the interaction described hereinabove betweenactuation sled 510 and staple pusher 160 and will not be discussed indetail. It is sufficient to note that staple pushers 260, 360 may befreely substituted for staple pusher 160.

Further embodiments of the present disclosure are illustrated in FIGS.52-56 and discussed in detail hereinafter. The embodiments that areillustrated in FIGS. 52-56 include a cam member or actuation bar. Anexample of a suitable cam bar and associated apparatus is disclosed inU.S. Pat. No. 6,619,529 to Green et al., currently owned by TycoHealthcare Group LP, the contents of which are hereby incorporated byreference in their entirety. In addition, the staple cartridge 40′ (FIG.3) may include longitudinal slots as disclosed in the '529 for providinglateral stability to the cam bars as they translate longitudinallythrough staple cartridge 40′. Referring initially to FIG. 52, a portionof a cam bar or actuation member 600 is illustrated. Actuation member600 includes a distal end 610 wherein distal end 610 includes the sameor substantially similar components as included in actuation sled 110(FIG. 11). Distal end 610 includes a base 612, a first camming member620, and a second camming member 640 (not shown). First and secondcamming members 620, 640 include respective first or leading cam wedges622, 642 and respective second or trailing cam wedges 624, 644. Theconfiguration and relationships between the components of distal end 610are substantially similar to those components of actuation sled 110 andwill not be described in detail herein. Essentially, distal end 610includes actuation sled 110 using reference characters 6xx in lieu of1xx used in describing actuation sled 110. In addition, actuation member600 and distal end 610 may be substituted for actuation sled 110 instaple cartridge 40′ (FIG. 4). The interaction of distal end 610 andstaple pusher 160 (FIG. 6) is substantially similar to the interactionof actuation sled 110 and staple pusher 160 (see FIGS. 16-17) and willnot be discussed in detail herein. Further still, distal end 610 isadapted to cooperate with staple pusher 260 (FIG. 26) or staple pusher360 (FIG. 28). As shown, cam wedges 622, 642 are laterally andlongitudinally offset and engage corresponding surfaces on the staplepusher (not shown) for improving the stability of the staple pusherduring firing, as described above with respect to cam wedges 122, 142.

In FIG. 53, a portion of an actuation member 700 is shown and includes adistal end 710 having the same or substantially similar components asincluded in actuation sled 210 (FIG. 19). Distal end 710 includes a base712, a first camming member 720, and a second camming member 740 (notshown). First and second camming members 720, 740 include respectivefirst or leading cam wedges 722, 742 and respective second or trailingcam wedges 724, 744. The configuration and relationships between thecomponents of distal end 710 are substantially similar to thosecomponents of actuation sled 210 and will not be described in detailherein. Essentially, distal end 710 includes actuation sled 210 usingreference characters 7xx in lieu of 2xx used in describing actuationsled 210. In addition, actuation member 700 and distal end 710 may besubstituted for actuation sled 210 in staple cartridge 40′. Theinteraction of distal end 710 and staple pusher 160 (FIG. 6) issubstantially similar to the interaction of actuation sled 210 andstaple pusher 160 (see FIGS. 22-23) and will not be discussed in detailherein. Further still, distal end 710 is adapted to cooperate withstaple pusher 260 (FIG. 26) or staple pusher 360 (FIG. 28). In thisembodiment, the lateral and longitudinal offset of the cam wedges areenhanced by providing drive surfaces wherein the first drive angle isless than the second drive angle. This arrangement of drive anglesenhances staple pusher stability, thereby minimizing tilting or rotationand further reduces uneven firing of staples 50.

FIG. 54 illustrates a portion of an actuation member 800 and includes adistal end 810 having the same or substantially similar components asactuation sled 310 (FIG. 30). Distal end 810 includes a base 812, afirst camming member 820, and a second camming member 840 (not shown).First and second camming members 820, 840 include respective first orleading cam wedges 822, 842 and respective second or trailing cam wedges824, 844. The configuration and relationships between the components ofdistal end 810 are substantially similar to those components ofactuation sled 310 and will not be described in detail herein.Essentially, distal end 810 includes actuation sled 310 using referencecharacters 8xx in lieu of 3xx used in describing actuation sled 310. Inaddition, actuation member 800 and distal end 810 may be substituted foractuation sled 310 in staple cartridge 40′. The interaction of distalend 810 and staple pusher 160 (FIG. 6) is substantially similar to theinteraction of actuation sled 310 and staple pusher 160 (see FIGS.35-36) and will not be discussed in detail herein. Further still, distalend 810 is adapted to cooperate with staple pusher 260 (FIG. 26) orstaple pusher 360 (FIG. 28). In this embodiment, the lateral andlongitudinal offset of the cam wedges improves the stability of thestaple pusher during firing.

FIG. 55 illustrates a portion of an actuation member 900 and includes adistal end 910 having the same or substantially similar components asactuation sled 410 (FIG. 37). Distal end 910 includes a base 912, afirst camming member 920, and a second camming member 940 (not shown).First and second camming members 920, 940 include respective first orleading cam wedges 922, 942 and respective second or trailing cam wedges924, 944. The configuration and relationships between the components ofdistal end 910 are substantially similar to those components ofactuation sled 410 and will not be described in detail herein.Essentially, distal end 910 includes actuation sled 410 using referencecharacters 9xx in lieu of 4xx used in describing actuation sled 410. Inaddition, actuation member 900 and distal end 910 may be substituted foractuation sled 410 in staple cartridge 40′. The interaction of distalend 910 and staple pusher 460 (FIG. 42A) is substantially similar to theinteraction of actuation sled 410 and staple pusher 460 (see FIGS.43-44) and will not be discussed in detail herein.

FIG. 56 illustrates a portion of an actuation member 1000 and includes adistal end 1010 having the same or substantially similar components asactuation sled 510 (FIG. 45). Distal end 1010 includes a base 1012, afirst camming member 1020, and a second camming member 1040 (not shown).First and second camming members 1020, 1040 include respective first orleading cam wedges 1022, 1042 and respective second or trailing camwedges 1024, 1044. The configuration and relationships between thecomponents of distal end 1010 are substantially similar to thosecomponents of actuation sled 510 and will not be described in detailherein. Essentially, distal end 1010 includes actuation sled 510 usingreference characters 10xx in lieu of 5xx used in describing actuationsled 510. In addition, actuation member 1000 and distal end 1010 may besubstituted for actuation sled 510 in staple cartridge 40′. Theinteraction of distal end 1010 and staple pusher 160 (FIG. 6) issubstantially similar to the interaction of actuation sled 510 andstaple pusher 160 (see FIGS. 50-51) and will not be discussed in detailherein. Further still, distal end 1010 is adapted to cooperate withstaple pusher 260 (FIG. 26) or staple pusher 360 (FIG. 28).

While the above description contains many specifics, these specificsshould not be construed as limitations on the scope of the presentdisclosure, but merely as exemplifications of preferred embodimentsthereof. Those skilled in the art will envision many other possiblevariations that are within the scope and spirit of the presentdisclosure. By way of example only, it is contemplated that the driveangles of various surfaces of the cam wedges may differ between camwedges of the same actuation mechanism or that the receiving angles ofthe staple pusher receiving surfaces may differ as between the cammembers of the same staple pusher, or both.

1. A staple pusher comprising: a body defining a longitudinal axis, thebody including: a first cam surface configured to facilitate cammingmotion and being angled at a first oblique angle relative to thelongitudinal axis, the first cam surface having a proximal end and adistal end; a second cam surface configured to facilitate camming motionand being angled at a second oblique angle relative to the longitudinalaxis, the second cam surface having a proximal end and a distal end,wherein the second cam surface is longitudinally and laterally offsetfrom the first cam surface; and at least one pusher plate supported bythe first and second cam surfaces, the at least one pusher plate havinga first end coupled to the body and a second end configured to receive astaple.
 2. The staple pusher of claim 1, wherein each cam surfacedefines a first receiving angle and a second receiving angle.
 3. Thestaple pusher of claim 2, wherein the first receiving angle is greaterthan the second receiving angle.
 4. The staple pusher of claim 3,wherein the first receiving angle is about 35° and the second receivingangle is about 20°.
 5. The staple pusher of claim 4, wherein the camsurfaces are substantially parallel to each other.
 6. The staple pusherof claim 5, wherein each pusher plate is substantially parallel to thecam surfaces.
 7. The staple pusher of claim 1, wherein the first camsurface is longitudinally offset from the second cam surface by abouttwo-thirds of a length of the at least one pusher plate.
 8. The staplepusher of claim 1, wherein the first oblique angle is different from thesecond oblique angle.
 9. The staple pusher of claim 1, wherein the firstand second cam surfaces define a gap therebetween.